EP3120915B1 - Milieux filtrants appropriés aux applications hydrauliques - Google Patents

Milieux filtrants appropriés aux applications hydrauliques Download PDF

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Publication number
EP3120915B1
EP3120915B1 EP16185286.8A EP16185286A EP3120915B1 EP 3120915 B1 EP3120915 B1 EP 3120915B1 EP 16185286 A EP16185286 A EP 16185286A EP 3120915 B1 EP3120915 B1 EP 3120915B1
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EP
European Patent Office
Prior art keywords
layer
fibers
microns
filter media
less
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EP16185286.8A
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German (de)
English (en)
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EP3120915A1 (fr
Inventor
Cameron Thomson
Milind Godsay
Randall Keisler
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Hollingsworth and Vose Co
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Hollingsworth and Vose Co
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D29/00—Filters with filtering elements stationary during filtration, e.g. pressure or suction filters, not covered by groups B01D24/00 - B01D27/00; Filtering elements therefor
    • B01D29/50—Filters with filtering elements stationary during filtration, e.g. pressure or suction filters, not covered by groups B01D24/00 - B01D27/00; Filtering elements therefor with multiple filtering elements, characterised by their mutual disposition
    • B01D29/56—Filters with filtering elements stationary during filtration, e.g. pressure or suction filters, not covered by groups B01D24/00 - B01D27/00; Filtering elements therefor with multiple filtering elements, characterised by their mutual disposition in series connection
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D29/00—Filters with filtering elements stationary during filtration, e.g. pressure or suction filters, not covered by groups B01D24/00 - B01D27/00; Filtering elements therefor
    • B01D29/0093—Making filtering elements not provided for elsewhere
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D39/00—Filtering material for liquid or gaseous fluids
    • B01D39/02—Loose filtering material, e.g. loose fibres
    • B01D39/06—Inorganic material, e.g. asbestos fibres, glass beads or fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D39/00—Filtering material for liquid or gaseous fluids
    • B01D39/14—Other self-supporting filtering material ; Other filtering material
    • B01D39/16—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres
    • B01D39/1607—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres the material being fibrous
    • B01D39/1623—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres the material being fibrous of synthetic origin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D39/00—Filtering material for liquid or gaseous fluids
    • B01D39/14—Other self-supporting filtering material ; Other filtering material
    • B01D39/20—Other self-supporting filtering material ; Other filtering material of inorganic material, e.g. asbestos paper, metallic filtering material of non-woven wires
    • B01D39/2003—Glass or glassy material
    • B01D39/2017—Glass or glassy material the material being filamentary or fibrous
    • G—PHYSICS
    • G06—COMPUTING; CALCULATING OR COUNTING
    • G06V—IMAGE OR VIDEO RECOGNITION OR UNDERSTANDING
    • G06V40/00—Recognition of biometric, human-related or animal-related patterns in image or video data
    • G06V40/20—Movements or behaviour, e.g. gesture recognition
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2201/00—Details relating to filtering apparatus
    • B01D2201/18—Filters characterised by the openings or pores
    • B01D2201/188—Multiple filtering elements having filtering areas of different size
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2239/00—Aspects relating to filtering material for liquid or gaseous fluids
    • B01D2239/06—Filter cloth, e.g. knitted, woven non-woven; self-supported material
    • B01D2239/0604—Arrangement of the fibres in the filtering material
    • B01D2239/064—The fibres being mixed
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2239/00—Aspects relating to filtering material for liquid or gaseous fluids
    • B01D2239/06—Filter cloth, e.g. knitted, woven non-woven; self-supported material
    • B01D2239/065—More than one layer present in the filtering material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2239/00—Aspects relating to filtering material for liquid or gaseous fluids
    • B01D2239/12—Special parameters characterising the filtering material
    • B01D2239/1233—Fibre diameter
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/249921—Web or sheet containing structurally defined element or component
    • Y10T428/249953—Composite having voids in a component [e.g., porous, cellular, etc.]
    • Y10T428/249962—Void-containing component has a continuous matrix of fibers only [e.g., porous paper, etc.]
    • Y10T428/249964—Fibers of defined composition
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/249921—Web or sheet containing structurally defined element or component
    • Y10T428/249953—Composite having voids in a component [e.g., porous, cellular, etc.]
    • Y10T428/249967—Inorganic matrix in void-containing component
    • Y10T428/249969—Of silicon-containing material [e.g., glass, etc.]

Definitions

  • the present invention relates generally to filter media which may be used in hydraulic applications and, more particularly, to multilayered filter media which have desirable performance characteristics.
  • Filter media can be used to remove contamination in a variety of applications.
  • the filter media may be designed to have different performance characteristics.
  • filter media may be designed to have performance characteristics suitable for hydraulic applications which involve filtering contamination in pressurized fluids.
  • filter media can be formed of a web of fibers.
  • the web may include microglass fibers amongst other components.
  • the fiber web provides a porous structure that permits fluid (e.g., hydraulic fluid) to flow through the filter media. Contaminant particles contained within the fluid may be trapped on the fibrous web.
  • Filter media characteristics such as fiber diameter and basis weight, affect filter performance including filter efficiency, dirt holding capacity and resistance to fluid flow through the filter.
  • filter media that can be used in hydraulic applications which has a desirable balance of properties including a high dirt holding capacity and a low resistance to fluid flow (high permeability) across the filter media.
  • US 2009/044702 A1 discloses a filter element having multiple formed layers of filtration media. The media are layered so as to form a pore size gradient.
  • Filter media including those suitable for hydraulic applications, and related components, systems, and methods associated therewith are provided.
  • the present invention provides a filter media comprising:
  • the filter media described above and herein may have a normalized resistance ratio of the second layer to the first layer is 4:1 or greater, and a normalized resistance ratio of the third layer to the second layer is 4:1 or less.
  • a normalized resistance ratio of the second layer to the first layer is between 4:1 and 6:1, and a normalized resistance ratio of the third layer to the second layer is between 2:1 and 4:1.
  • the first layer may include less than about 20 wt% synthetic fibers.
  • the first layer is a pre-filter layer and has a basis weight greater than the basis weight of the second layer. At least one of the first and second layers may comprises at least about 80 wt% glass fibers.
  • At least one of the first and second layers comprises at least about 40 wt% or 60 wt% microglass fibers.
  • the microglass fibers may have an average diameter of between 1 ⁇ m and 6 ⁇ m.
  • the ratio of the first and second average diameters may be less than 2:1.
  • the third average diameter may be less than about 1 micron.
  • at least one of the first, second and third layers may have a basis weight of less than about 40 g/m 2 .
  • the synthetic polymer fibers of a layer may comprise meltblown fibers.
  • the synthetic polymer fibers may comprise a material selected from the group consisting of, for example, polyester, nylon, and polyphenylene sulfide.
  • the third layer has a thickness of less than 200 microns.
  • the third layer may have a basis weight of from about 20 g/m 2 to about 30 g/m 2 .
  • the filter media described above and herein may have an overall dirt holding capacity of at least about 180 g/m 2 , or at least about 230 g/m 2 .
  • the filter media may have an overall permeability of greater than about 35 cfm/sf, or greater than about 40 cfm/sf.
  • the filter media may be used to form a hydraulic filter element in some embodiments.
  • the third layer is downstream of the second layer, and the second layer is downstream of the first layer. Other configurations are also possible.
  • a method of filtering a liquid comprising passing a liquid including particulates through a filter media.
  • the filter media can include one of the filter media described above and/or herein.
  • Filter media including those suitable for hydraulic applications, and related components, systems, and methods associated therewith are provided.
  • the filter media described herein may include three or more layers, at least one of the layers having a relatively high percentage of microglass fibers. Additionally, the filter media may be designed such that the ratio of average fiber diameters between two layers is relatively small, which can lead to a relatively low resistance ratio between the layers.
  • each of the three layers of the filter media comprises synthetic polymer fibers.
  • Certain filter media described herein may have desirable properties including high dirt holding capacity and a low resistance to fluid flow. The media may be incorporated into a variety of filter element products including hydraulic filters.
  • a filter media 10 includes a first layer 20 adjacent a second layer 30 and a third layer 40 adjacent the second layer. Additional layers, e.g., fourth, fifth, or sixth layers, may also be included in some cases.
  • the orientation of filter media 10 relative to fluid flow through the media can generally be selected as desired.
  • first layer 20 is upstream of second layer 30 in the direction of fluid flow indicated by arrow 50. In other embodiments, however, first layer 20 is downstream of the second layer in the direction of fluid flow through the filter media.
  • a layer when referred to as being "adjacent" another layer, it can be directly adjacent the layer, or an intervening layer also may be present.
  • a layer that is "directly adjacent” or “in contact with” another layer means that no intervening layer is present.
  • first layer 20 is a pre-filter layer (also known as an "loading layer") and second layer 30 is a main filter layer (also known as an "efficiency layer").
  • a pre-filter layer is formed using coarser fibers, and therefore has a lower resistance to fluid flow, than that of a main filter layer.
  • the one or more main filter layers may include finer fibers and have a higher resistance to fluid flow than that of a pre-filter layer. As such, a main filter layer can generally trap particles of smaller size compared to the pre-filter layer.
  • the third layer may be an additional main filter layer that has different properties as second layer 30.
  • the third layer has even finer fibers and a higher resistance to fluid flow than that of second layer 30.
  • the third layer comprises synthetic polymer fibers as described in more detail below.
  • the filter media can also have other configurations of first, second, third or optionally more layers.
  • filter media 10 does not include a pre-filter layer.
  • first layer 20 is an upstream main filter layer and second layer 30 is a main filter layer downstream of the first layer.
  • the filter media includes a third layer 40 (e.g., another main filter layer) positioned downstream of the second layer.
  • An upstream layer may have coarser fibers, and therefore a lower resistance to fluid flow, than that of a layer downstream of that layer. In some cases, the resistance of each layer increases successively from the furthest upstream layer to the furthest downstream layer.
  • a layer having relatively coarse fibers may be positioned between two layers having relatively finer fibers.
  • Other configurations are also possible.
  • a filter media may include any suitable number of layers, e.g., at least 3, 4, 5, 6, 7, 8, or 9 layers, depending on the particular application and performance characteristics desired.
  • the first, second and third layers include fibers having different fiber diameters. They may have other different characteristics (e. g. fiber compositions and fiber lengths). Fibers with different characteristics can be made from one material (e.g., by using different process conditions) or different materials (e.g., glass fibers, synthetic fibers (e.g., organic polymer fibers), and combinations thereof). Without wishing to be bound by theory, it is believed that a filter media having a multilayered structure with layers including different characteristics exhibits significantly improved performance properties such as dirt holding capacity and/or efficiency compared to a filter media having a single-layered structure.
  • one or more layers of filter media 10 includes microglass fibers, chopped strand glass fibers, or a combination thereof.
  • Microglass fibers and chopped strand glass fibers are known to those skilled in the art. One skilled in the art is able to determine whether a glass fiber is microglass or chopped strand by observation (e.g., optical microscopy, electron microscopy). Microglass fibers may also have chemical differences from chopped strand glass fibers. In some cases, though not required, chopped strand glass fibers may contain a greater content of calcium or sodium than microglass fibers. For example, chopped strand glass fibers may be close to alkali free with high calcium oxide and alumina content.
  • Microglass fibers may contain 10-15% alkali (e.g., sodium, magnesium oxides) and have relatively lower melting and processing temperatures.
  • alkali e.g., sodium, magnesium oxides
  • the terms refer to the technique(s) used to manufacture the glass fibers. Such techniques impart the glass fibers with certain characteristics.
  • chopped strand glass fibers are drawn from bushing tips and cut into fibers in a process similar to textile production. Chopped strand glass fibers are produced in a more controlled manner than microglass fibers, and as a result, chopped strand glass fibers will generally have less variation in fiber diameter and length than microglass fibers.
  • Microglass fibers are drawn from bushing tips and further subjected to flame blowing or rotary spinning processes. In some cases, fine microglass fibers may be made using a remelting process. In this respect, microglass fibers may be fine or coarse. As used herein, fine microglass fibers are less than 1 micron in diameter and coarse microglass fibers are greater than or equal to 1 micron in diameter.
  • the microglass fibers of one or more layers can have small diameters such as less than 10.0 microns.
  • the average diameter of the microglass fibers in a layer may be between 0.1 microns to about 9.0 microns; and, in some embodiments, between about 0.3 microns and about 6.5 microns, or between about 1.0 microns and 5.0 microns.
  • the microglass fibers may have an average fiber diameter of less than about 7.0 microns, less than about 5.0 microns, less than about 3.0 microns, or less than about 1.0 microns.
  • Average diameter distributions for microglass fibers are generally log-normal. However, it can be appreciated that microglass fibers may be provided in any other appropriate average diameter distribution (e.g., Gaussian distribution).
  • the microglass fibers may vary significantly in length as a result of process variations.
  • the aspect ratios (length to diameter ratio) of the microglass fibers in a layer may be generally in the range of about 100 to 10,000. In some embodiments, the aspect ratio of the microglass fibers in a layer are in the range of about 200 to 2500; or, in the range of about 300 to 600. In some embodiments, the average aspect ratio of the microglass fibers in a layer may be about 1,000; or about 300. It should be appreciated that the above-noted dimensions are not limiting and that the microglass fibers may also have other dimensions.
  • Coarse microglass fibers, fine microglass fibers, or a combination of microglass fibers thereof may be included within a layer.
  • coarse microglass fibers make up between about 20% by weight and about 90% by weight of the glass fibers.
  • coarse microglass fibers make up between about 30% by weight and about 60% by weight of the glass fibers, or between about 40% by weight and about 60% by weight of the glass fibers.
  • the fine microglass fibers make up between about 0% and about 70% by weight of the glass fibers.
  • fine microglass fibers make up between about 5% by weight and about 60% by weight of the glass fibers, or between about 30% by weight and about 50% by weight of the glass fibers.
  • the chopped strand glass fibers may have an average fiber diameter that is greater than the diameter of the microglass fibers.
  • the chopped strand glass fiber has a diameter of greater than about 5 microns.
  • the diameter range may be up to about 30 microns.
  • the chopped strand glass fibers may have a fiber diameter between about 5 microns and about 12 microns.
  • the chopped strand fibers may have an average fiber diameter of less than about 10.0 microns, less than about 8.0 microns, less than about 6.0 microns.
  • Average diameter distributions for chopped strand glass fibers are generally log-normal. Chopped strand diameters tend to follow a normal distribution.
  • chopped strand glass fibers may be provided in any appropriate average diameter distribution (e.g., Gaussian distribution).
  • chopped strand glass fibers may have a length in the range of between about 0.318 cm (0.125 inches) and about 2.54 cm (1 inch) (e.g., about or 0.635 cm (0.25 inches), or about 1.27 cm (0.5 inches)).
  • microglass and/or chopped strand fibers may also have other dimensions.
  • one or more layers of filter media 10 includes a relatively large percentage of microglass fibers compared to chopped strand glass fibers.
  • at least 70 wt%, or at least 80 wt%, at least 90 wt%, at least 93 wt%, at least 95 wt%, at least 97 wt%, or at least 99 wt% of the fibers of a layer may be microglass fibers.
  • all of the fibers of a layer are microglass fibers.
  • one or more layers of filter media 10 includes a relatively large percentage of microglass fiber with respect to all of the components used to form the layer.
  • one or more layers may include at least about 40 wt%, at least about 50 wt%, at least about 60 wt%, at least about 70 wt%, or at least about 80 wt%, at least about 90 wt%, at least about 93 wt%, at least about 95 wt%, at least about 97 wt%, or at least about 99 wt% of microglass fiber.
  • one or more layers includes between about 90 wt% and about 99 wt%, e.g., between about 90 wt% and about 95 wt% microglass fibers. In another embodiment, one or more layers includes between about 40 wt% to about 80 wt% microglass fibers, or between about 60 wt% to about 80 wt% microglass fibers. It should be understood that, in certain embodiments, one or more layers of the filter media do not include microglass fiber within the above-noted ranges or at all.
  • any suitable amount of chopped strand fibers can be used in one or more layers of a filter media.
  • one or more layers includes a relatively low percentage of chopped strand fibers.
  • one or more layers may include less than 30 wt%, or less than 20 wt%, or less than 10 wt%, or less than 5 wt%, or less than 2 wt%, or less than 1 wt% of chopped strand fiber.
  • one or more layers of a filter media does not include any chopped strand fibers. It should be understood that, in certain embodiments, one or more layers of the filter media do not include chopped strand fibers within the above-noted ranges.
  • One or more layers of filter media 10 may also include microglass fibers having an average fiber diameter within a certain range and making up a certain range of weight percentage of the layer.
  • one or more layers of a filter media may include microglass fibers having an average fiber diameter of less than 5 microns making up less than about 50%, less than about 40%, less than about 30%, less than about 20%, less than about 10%, or less than about 5% of the microglass fibers of the layer.
  • a layer includes 0% of microglass fibers having an average diameter of less than 5 microns.
  • the one or more layers of the filter media may include microglass fibers having an average fiber diameter of greater than or equal to 5 microns making up greater than about 50%, greater than about 60%, greater than about 70%, greater than about 80%, greater than about 90%, greater than about 93%, or greater than about 97% of the microglass fibers of the layer.
  • more than one layer of a filter media includes such properties. It should be understood that, in certain instances, one or more layers of the filter media include microglass fibers within ranges different than those described above.
  • one or more layers of a filter media includes relatively fine fibers.
  • one or more layers of the filter media may include microglass fibers having an average fiber diameter of less than 5 microns making up greater than about 50%, greater than about 60%, greater than about 70%, greater than about 80%, greater than about 90%, greater than about 93%, or greater than about 97% of the microglass fibers of the layer.
  • the one or more layers of the filter media may include microglass fibers having an average fiber diameter of greater than or equal to 5 microns making up less than about 50%, less than about 40%, less than about 30%, less than about 20%, less than about 10%, or less than about 5% of the microglass fibers of the layer.
  • a layer includes 0% of microglass fibers having an average diameter of greater than or equal to 5 microns. In some cases, more than one layer of a filter media includes such properties. It should be understood that, in certain instances, one or more layers of the filter media include microglass fibers within ranges different than those described above.
  • one or more layers of filter media 10 includes a large percentage of glass fiber (e.g., microglass fibers and/or chopped strand glass fibers).
  • one or more layers may comprise at least about 40 wt%, at least about 50 wt%, at least about 60 wt%, at least about 70 wt%, at least about 80 wt%, at least about 90 wt%, or at least about 95 wt% of glass fiber.
  • all of the fibers of a layer are formed of glass. It should be understood that, in certain embodiments, one or more layers of the filter media do not include glass fiber within the above-noted ranges or at all.
  • fibers having a fiber diameter less than or equal to 7 microns make up greater than about 60% by weight of the fibers, greater than about 70% by weight of the fibers, or greater than about 80% by weight of the fibers of a layer.
  • fibers having a fiber diameter less than or equal to 5 microns make up greater than about 60% by weight of the fibers, greater than about 70% by weight of the fibers, or greater than about 80% by weight of the fibers of a layer.
  • fibers having a fiber diameter less than or equal to 3 microns make up greater than about 50% by weight of the fibers, greater than about 60% by weight of the fibers, or greater than about 70% by weight of the fibers of a layer.
  • a filter media includes a first layer (e.g., a pre-filter layer) having an average fiber diameter of between about 1.0 microns and about 10.0 microns, e.g., between about 1.0 micron and about 8.0 microns.
  • a second layer of the filter media e.g., a main filter layer
  • the third layer (e.g., downstream of the second layer), may have an average fiber diameter of between about 0.1 microns and about 1.5 microns or between about 0.8 micron and about 5.0 microns, e.g., between about 0.5 micron and about 2.5 microns or between about 0.1 and about 1.5 microns, as described below. Additional layers are also possible.
  • the third layer may be formed of fibers having an average diameter of less than about 1.5 microns (e.g., from about 0.1 microns to about 1.5 microns, from about 0.2 microns to about 1.5 microns, from about 0.3 microns to about 1.5 microns, from about 0.3 microns to about 1.4 microns, from about 0.4 microns to about 1.3 microns, from about 0.1 microns to about 0.5 microns, from about 0.1 micron to about 0.2 microns, from about 0.1 microns to about 0.3 microns, from about 0.5 microns to about 1.5 microns, from about 0.5 microns to about 1.0 micron, from about 0.7 microns to about 1.0 micron, from about 0.2 microns to about 0.8 microns, from about 0.2 microns to about 0.5 microns, from about 0.3 microns to about 0.5 microns, from about 0.4 microns to about 0.5 microns, from about 0.4 microns to about
  • the third layer includes fibers formed of a synthetic polymer.
  • the third layer is manufactured from a mcltblown process, and may be formed of fibers having an average diameter of less than about 1.5 microns (e.g., less than about 1.4 microns, less than about 1.3 microns, less than about 1.2 microns, less than about 1.1 microns, less than about one micron), and/or at least about 0.2 microns (e.g., at least about 0.3 microns, at least about 0.4 microns, at least about 0.5 microns), as measured using scanning electron microscopy.
  • the synthetic polymer layer (e.g., meltblown layer) is formed of fibers having an average diameter of from about 0.2 microns to about 1.5 microns (e.g., from about 0.3 microns to about 1.5 microns, from about 0.3 microns to about 1.4 microns, from about 0.4 micron to about 1.3 microns, from about 0.7 microns to about 1.0 micron,).
  • the synthetic polymer layer (e.g., meltblown layer) is formed of fibers having an average diameter of from about 0.2 microns to about 1.5 microns (e.g., from about 0.5 microns to about 1.5 microns, from about 0.5 microns to about 1.0 micron, from about 0.2 microns to about 0.8 microns, from about 0.2 microns to about 0.5 microns, from about 0.3 microns to about 0.5 microns, from about 0.4 microns to about 0.5 microns, from about 0.4 microns to about 0.6 microns, from about 0.4 microns to about 0.8 microns, from about 0.2 microns to about 0.4 microns, from about 0.2 microns to about 0.3 microns, from about 0.3 microns to about 0.4 microns).
  • At least about 5% e.g., at least about 10%, at least about 25%, at least about 50%, at least about 60%, at least about 75%) of the fibers in the synthetic material extend a distance of at least 0.3 microns in a direction substantially perpendicular to a surface of a third layer.
  • the synthetic polymer fibers are formed from a process such as a meltblown, a meltspun, a melt electrospinning and/or a solvent electrospinning process and the fibers have one of the fiber diameter ranges listed above.
  • filter media 10 is designed such that the average fiber diameters of each layer are different.
  • the ratio of average fiber diameters between two layers may be less than 10:1, less than 7:1, less than 5:1, less than 4:1, less than 3:1, less than 2:1, or less than 1:1.
  • Small differences in average fiber diameters between two layers may, in some instances, lead to relatively low resistance ratios between the layers.
  • relatively low resistance ratios between the layers can result in the filter media having favorable properties such as high dirt holding capacity at relatively low basis weights, as described in more detail below.
  • two layers may have larger differences in average fiber diameters.
  • the ratio of average fiber diameters between two layers may be greater than 1:1, greater than 2:1, greater than 3:1, greater than 4:1, greater than 5:1, greater than 7:1, or greater than 10:1.
  • the third layer may be formed of fibers having an average length.
  • the third layer may be formed of fibers having an average length from about 0.254 cm (0.1 inches) to about 2540 cm (1,000 inches) or between about 2.54 cm (1 inch) and about 254 cm (100 inches).
  • the fibers in the third layer may have an average aspect ratio.
  • fibers in a third layer may have an average aspect ratio between about 5 and about 1,000,000 or between about 10 and about 100,000.
  • the third layer can generally have any suitable thickness of less than about 200 microns, less than about 180 microns, less than about 150 microns) thick.
  • the third layer can be from about 10 microns to about 200 microns, from about 20 microns to about 150 from about 50 microns to about 100 microns) thick.
  • Thickness is determined according to TAPPI T411 using an appropriate caliper gauge (e.g., a Model 200-A electronic microgauge manufactured by Emveco, tested at 1.5 psi). In some cases, if the thickness of a layer cannot be determined using an appropriate caliper gauge, visual techniques such as scanning electron microscopy in cross-section view can be used.
  • the basis weight of the third layer can typically be selected as desired.
  • the basis weight of the third layer is at least about 1 g/m 2 (e.g., at least about 10 g/m 2 , at least about 25 g/m 2 ), and/or less than about 100 g/m 2 (less than about 90 g/m 2 , less than about 75 g/m 2 , less than about 40 g/m 2 , less than about 30 g/m 2 , less than about 25 g/m 2 , or less than about 20 g/m 2 ).
  • the third layer has a basis weight of from about 1 g/m 2 to about 100 g/m 2 (e.g., from about 10 g/m 2 to about 90 g/m 2 , from about 20 g/m 2 to about 30 g/m 2 , from about 15 g/m 2 to about 40 g/m 2 , from about 25 g/m 2 to about 75 g/m 2 , from about 2 g/m 2 to about 20 g/m 2 , from about 4 g/m 2 to about 12 g/m 2 ).
  • the mean flow pore size of the third layer can vary as desired in the range between about 5 microns and about 50 microns, between about 10 microns and about 30 microns, between about 10 microns and about 20 microns, between 5 microns and 15 microns, between about 8 microns and about 12 microns, between about 1 micron and about 5 microns, between about 5 microns and about 9 microns, or between about 13 microns and about 17 microns.
  • the mean flow pore size refers to the mean flow pore size measured by using a Capillary Flow Porometer manufactured by Porous Materials, Inc in accordance with the ASTM F316-03 standard.
  • the air permeability of the third layer can also be varied as desired.
  • the third layer has an air permeability of less than about 0.24 m 3 /s (500 CFM) (e.g., less than about 0.12 m 3 /s (250 CFM), less than about 0.09 m 3 /s (200 CFM)), and or at least about 0.01 m 3 /s (20 CFM) (e.g., at least about 0.02 m 3 /s (50 CFM), at least about 0.05 m 3 /s (100 CFM)).
  • the air permeability of the third layer can be from about 0.01 m 3 /s (20 CFM) to about 0.24 m 3 /s (500 CFM) (e.g., from about 0.02 m 3 /s (50 CFM) to about 0.12 m 3 /s (250 CFM), from about 0.05 m 3 /s (100 CFM) to about 0.09 m 3 /s (200 CFM)).
  • the layers of the filter media according to the invention include components such as synthetic fibers (e.g., synthetic polymer fibers).
  • one or more layers of filter media 10 may include a relatively high percentage of synthetic fibers, e.g., at least about 50 wt%, at least about 60 wt%, at least about 70 wt%, at least about 80 wt%, at least about 90 wt%, at least about 95 wt%, at least about 97 wt%, at least about 99 wt%, or 100 wt% synthetic fibers (e.g., synthetic polymer fibers).
  • synthetic fibers may be beneficial for resistance to moisture, heat, long-term aging, and microbiological degradation.
  • synthetic fibers comprise a small weight percentage of the filter media.
  • one or more layers of the filter media may include less than or equal to about 25 wt%, less than or equal to about 15 wt%, less than or equal to about 5 wt%, or less than or equal to about 2 wt% of synthetic fibers.
  • one or more layers of a filter media do not include any synthetic fiber.
  • synthetic fibers may also be possible for synthetic fibers to be incorporated within the filter media outside of the ranges disclosed.
  • the synthetic fibers may enhance adhesion of the glass fibers within the web during processing.
  • Synthetic fibers may be, for example, binder fibers, bicomponent fibers (e.g., bicomponent binder fibers) and/or staple fibers.
  • the synthetic fibers in any layer may have any suitable composition.
  • the synthetic fibers comprise a thermoplastic.
  • the synthetic fibers include PVA (polyvinyl alcohol), polyester (e.g., polybutylene terephthalate, polybutylene naphthalate), polyethylene, polypropylene, acrylic, polyolefin, polyamides (e.g., nylon), rayon, polycarbonates, polyphenylene sulfides, polystyrenes, polybutylene terephthalate, and polyurethanes (e.g., thermoplastic polyurethanes), regenerated cellulose and combinations thereof.
  • the polymer(s) may contain fluorine atoms.
  • the synthetic fiber is chemically stable with hydraulic fluids for hydraulic applications.
  • the synthetic fiber may be formed by any suitable process such as meltblown, meltspun, melt electrospinning and/or solvent electrospinning processes.
  • the synthetic fibers are bicomponent fibers.
  • Each component of the bicomponent fiber can have a different melting temperature.
  • the fibers can include a core and a sheath where the activation temperature of the sheath is lower than the melting temperature of the core. This allows the sheath to melt prior to the core, such that the sheath binds to other fibers in the layer, while the core maintains its structural integrity. This is particularly advantageous in that it creates a more cohesive layer for trapping filtrate.
  • the core/sheath binder fibers can be concentric or non-concentric, and exemplary core/sheath binder fibers can include the following: a polyester core/copolyester sheath, a polyester core/polyethylene sheath, a polyester core/polypropylene sheath, a polypropylene core/polyethylene sheath, and combinations thereof.
  • Other exemplary bicomponent fibers can include split fiber fibers, side-by-side fibers, and/or "island in the sea" fibers.
  • one or more layers of the filter media can include other fiber types such as cellulose pulp fibers (e.g., wood pulp fibers).
  • the filter media may also include a binder.
  • the binder typically comprises a small weight percentage of the filter media.
  • the binder may comprise less than about 10 wt%, or less than about 5 wt% (e.g., between about 2 wt% and about 5 wt%) of the filter media.
  • the binder may be about 4 wt% of the filter media.
  • the binder may be added to the fibers in the wet fiber web state.
  • the binder coats the fibers and is used to adhere fibers to each other to facilitate adhesion between the fibers.
  • the binder may have any suitable composition.
  • the binder is resin-based.
  • the binder may be in the form of one or more components, for example, the binder may be in the form of bicomponent fibers such as the ones described above. Though, it should be understood that not all embodiments include all of these components and that other appropriate additives may be incorporated.
  • the filter media may include a variety of other suitable additives (typically, in small weight percentages) such as, surfactants, coupling agents, crosslinking agents, amongst others.
  • the fiber media may have a variety of desirable properties and characteristics which make it particularly well-suited for hydraulic applications.
  • the filter media described herein are not limited to hydraulic applications, and that the media can be used in other applications such as for air filtration or filtration of other liquids and gases.
  • Filter media 10 including one or more layers of the filter media, can also have varying basis weights, pore sizes, thicknesses, permeabilities, dirt holding capacities, efficiencies, and pressure drop, depending upon the requirements of a desired application.
  • the overall basis weight of a filter media can vary depending on factors such as the strength requirements of a given filtering application, the number of layers in the filter media, the position of the layer (e.g., upstream, downstream, middle), and the materials used to form the layer, as well as the desired level of filter efficiency and permissible levels of resistance or pressure drop.
  • increased performance e.g., lower resistance or pressure drop
  • the filter media includes multiple layers having different properties, where each layer has a relatively low basis weight, compared to certain single- or multi-layered media.
  • some such filter media may also have a lower overall basis weight while achieving high performance characteristics.
  • the overall basis weight of a filter media may range from between about 20 and 200 g/m 2 , or between about 90 g/m 2 and 150 g/m 2 .
  • the overall basis weight is less than about 200 g/m 2 , less than about 170 g/m 2 , less than about 150 g/m 2 , less than about 130 g/m 2 , less than about 120 g/m 2 , less than about 110 g/m 2 , less than about 100 g/m 2 , less than about 90 g/m 2 , less than about 80 g/m 2 , less than about 70 g/m 2 , less than about 70 g/m 2 , or less than about 60 g/m 2 .
  • the basis weight of the filter media is measured according to the Technical Association of the Pulp and Paper Industry (TAPPI) Standard T410. The values are expressed in grams per square meter or pounds per 3,000 square feet. Basis weight can generally be measured on a laboratory balance that is accurate to 0.1 grams.
  • TAPPI Technical Association of the Pulp and Paper Industry
  • one or more of an upstream layer, a downstream layer, a pre-filter layer, a main filter layer, a first layer, a second layer, or a third layer of filter media 10 may have a relatively low basis weight. Decreasing the basis weight of one or more layers can, in some embodiments, allow the filter media to have additional layers (e.g., at least three layers), while keeping the overall basis weight relatively low or within a certain range.
  • the basis weight of one or more such layers may range from between about 10 and about 100 g/m 2 , between about 20 g/m 2 and about 70 g/m 2 , or between about 20 g/m 2 and about 50 g/m 2 .
  • the basis weight of one or more layers such as a first, second and/or third layer (or the combination of two or more layers) of a filter media is less than about 100 g/m 2 , less than about 90 g/m 2 , less than about 80 g/m 2 , less than about 70 g/m 2 , less than about 60 g/m 2 , less than about 50 g/m 2 , less than about 40 g/m 2 , less than about 30 g/m 2 , less than about 20 g/m 2 , or less than about 10 g/m 2 .
  • a filter media includes a first layer (e.g., a pre-filter layer) having a basis weight of between about 5 g/m 2 and about 70 g/m 2 , e.g., between about 40 g/m 2 and about 60 g/m 2 .
  • the filter media may include a second layer (e.g., a first main filter layer) adjacent (e.g., directly adjacent) the first layer and have a basis weight between about 5 g/m 2 and about 70 g/m 2 , e.g., between about 30 g/m 2 and about 40 g/m 2 .
  • the filter media includes a third layer (e.g., a second main filter layer or a synthetic polymer layer) adjacent (e.g., directly adjacent) the second layer, which may have a basis weight between about 5 g/m 2 and about 70 g/m 2 , e.g., between about 30 g/m 2 and about 40 g/m 2 . Additional layers and ranges of basis weight are also possible.
  • a third layer e.g., a second main filter layer or a synthetic polymer layer
  • a synthetic polymer layer adjacent (e.g., directly adjacent) the second layer, which may have a basis weight between about 5 g/m 2 and about 70 g/m 2 , e.g., between about 30 g/m 2 and about 40 g/m 2 . Additional layers and ranges of basis weight are also possible.
  • the ratio of basis weights between two different layers of a filter media can vary depending on the desired properties of the filter media.
  • an upstream layer of a filter media e.g., a pre-filter layer
  • a downstream layer e.g., a main filter layer
  • the ratio of basis weights between an upstream layer and a downstream layer may be greater than 1:1, greater than 1.5:1, or greater than 2:1.
  • an upstream layer of a filter media has a smaller basis weight than that of a downstream layer, e.g., the ratio of basis weights between an upstream layer and a downstream layer may be less than 2:1, less than 1.5:1, or less than 1:1. In certain embodiments, the basis weight ratio of an upstream and a downstream layer is 1:1.
  • the overall thickness of a filter media may be between about 127 ⁇ m (5 mils) and 7620 ⁇ m (300 mils), e.g., between about 1270 ⁇ m (50 mils) and about 5080 ⁇ m (200 mils).
  • the thickness of a layer of the filter media may be between about 76 ⁇ m (3 mils) and about 2540 ⁇ m (100 mils), between about 76 ⁇ m (3 mils) and about 1778 ⁇ m (70 mils), between about 76 ⁇ m (3 mils) and about 1524 ⁇ m (60 mils), between about 76 ⁇ m (3 mils) and about 1270 ⁇ m (50 mils), between about 76 ⁇ m (3 mils) and about 1016 ⁇ m (40 mils), between about 76 ⁇ m (3 mils) and about 760 ⁇ m (30 mils), between about 76 ⁇ m (3 mils) and about 508 ⁇ m (20 mils), or between about 76 ⁇ m (3 mils) and about 254 ⁇ m
  • a filter media includes a first layer (e.g., a pre-filter layer) having a thickness of between about 76 ⁇ m (3 mils) and about 1778 ⁇ m (70 mils), e.g., between about 381 ⁇ m (15 mils) and about 508 ⁇ m (20 mils).
  • the filter media may include a second layer (e.g., a main filter layer) having a thickness of between about 76 ⁇ m (3 mils) and about 1524 (60 mils), e.g., between about 127 ⁇ m (5 mils) and about 254 ⁇ m (10 mils).
  • the filter media includes a third layer (e.g., downstream of the second layer) having a thickness of less than 200 ⁇ m. Additional layers are also possible.
  • the air permeability of filter media 10 can usually be selected as desired.
  • the overall permeability of the filter media may range from between about 1,016 m 3 /sec/m 2 (2 cubic feet per minute per square foot (cfm/sf)) and about 127 m 3 /min/m 2 (250 cfm/sf) between about 3,55 m 3 /sec/m 2 (7 cfm/sf) and about 101,6 m 3 /sec/m 2 (200 cfm/sf) between about 7,62 m 3 /sec/m 2 (215 cfm/sf) and about 68, 58 m3/sec/m 2 (135 cfm/sf), between about 7,62 m3/sec/m2 (15 cfm/sf) and about 25,4 m 3 / sec/m 2 (50 cfm/sf), between about 1,016 m 3 /sec/m 2 (2 cfm/sf) and about 25,4 m 3 / sec/
  • the permeability of the filter media is measured according to TAPPI Method T251.
  • the permeability of a filter media is an inverse function of flow resistance and can be measured with a Frazier Permeability Tester.
  • the Frazier Permeability Tester measures the volume of air per unit of time that passes through a unit area of sample at a fixed differential pressure across the sample. Permeability can be expressed in cubic feet per minute per square foot at a 1.27 cm (0.5 inch) water differential.
  • each layer of filter media 10 can also vary.
  • one or more layers of the filter media e.g., an upstream layer, a downstream layer, a first layer, a second layer, a third layer, etc.
  • a multi-layered filter media includes an overall permeability of between about 1,16 m 3 /sec/m 2 (2 cfm/sf) and about 101,6 m 3 /sec/m 2 (200 cfm/sf), e.g., between about 1,524 m 3 /sec/m 2 3 cfm/sf) and about 25,4 m 3 /sec/m 2 (50 cfm/sf).
  • the filter media may include a first layer (e.g., a pre-filter layer) having a permeability of between about 1,524 m 3 /sec/m 2 (3 cfm/sf) and about 2032 m 3 /sec/m 2 (4000 cfm/sf), e.g., between about 7,62 m 3 /sec/m 2 (15 cfm/sf) and about 355 m 3 / sec/m 2 (700 cfm/sf).
  • a first layer e.g., a pre-filter layer having a permeability of between about 1,524 m 3 /sec/m 2 (3 cfm/sf) and about 2032 m 3 /sec/m 2 (4000 cfm/sf), e.g., between about 7,62 m 3 /sec/m 2 (15 cfm/sf) and about 355 m 3 / sec/m 2 (700 cfm/sf).
  • the filter media may include a second layer (e.g., adjacent a pre-filter layer, if present) having a permeability of between about 2,032 m 3 /sec/m 2 (4 cfm/sf) and about 406,4 m 3 /sec/m 2 (800 cfm/sf), e.g., between about 3,556 m 3 /sec/m 2 (7 cfm/sf) and about 203,2 m 3 /sec/m 2 (400 cfm/sf).
  • a second layer e.g., adjacent a pre-filter layer, if present
  • a permeability of between about 2,032 m 3 /sec/m 2 (4 cfm/sf) and about 406,4 m 3 /sec/m 2 (800 cfm/sf), e.g., between about 3,556 m 3 /sec/m 2 (7 cfm/sf) and about 203,2 m 3 /sec/m
  • the permeability of the third layer may be between about 1,016 m 3 /sec/m 2 (2 cfm/sf) and about 152,4 m 3 /sec/m 2 (300 cfm/sf), e.g., between about 2,032 m 3 /sec/m 2 (4 cfm/sf) and about 30,48 m 3 /sec/m 2 (60 cfm/sf).
  • one or more layers of a filter media has a permeability greater than or equal to about 10,16 m 3 /sec/m 2 (20 cfm/sf), greater than or equal to about 25,4 m 3 /sec/m 2 (50 cfm/sf), greater than or equal to about 40,64 m 3 /sec/m 2 (80 cfm/sf), greater than or equal to about 50,8 m 3 /sec/m 2 (100 cfm/sf), greater than or equal to about 66,04 m 3 /sec/m 2 (130 cfm/sf), greater than or equal to about 81,28 m 3 /sec/m 2 (160 cfm/sf), greater than or equal to about 96,52 m 3 /sec/m 2 (190 cfm/sf), greater than or equal to about 106,68 m 3 /sec/m 2 (210 cfm/sf), greater than or equal to about 116,84
  • one or more layers of a filter media has a permeability less than or equal to about 127 m 3 /sec/m 2 (250 cfm/sf), than or equal to about 111,76 m 3 /sec/m 2 (220 cfm/sf), less than or equal to about 96,52 m 3 /sec/m 2 (190 cfm/sf), less than or equal to about 81,28 m 3 /sec/m 2 (160 cfm/sf), less than or equal to about 71,28 m 3 /sec/m 2 (140 cfm/sf), less than or equal to about 60,96 m 3 /sec/m 2 (120 cfm/sf), less than or equal to about 50,8 m 3 /sec/m 2 (100 cfm/sf), less than or equal to about 40,64 m 3 /sec/m 2 (80 cfm/sf), less than or equal to about 25,4
  • an upstream layer e.g., a pre-filter layer or a top layer of a main filter layer
  • a filter media has a permeability of greater than or equal to about 50,8 m 3 /sec/m 2 (100 cfm/sf), greater than or equal to about 76,2 m 3 /sec/m 2 (150 cfm/sf), or greater than or equal to about 101,6 m 3 /sec/m 2 (200 cfm/sf), and a downstream layer has a permeability of less than or equal to about 101,6 m 3 /sec/m 2 (200 cfm/sf), less than or equal to about 76,2 m 3 /sec/m 2 (150 cfm/sf), less than or equal to about 50,8 m 3 /sec/m 2 (100 cfm/sf), less than or equal to about 25,4 m 3 /sec/m 2 (50 cfm/sf).
  • Certain filter media can have relatively low resistance ratios or certain ranges of resistance ratios between two layers that provide favorable filtration properties.
  • the resistance ratio between a second layer, which includes fibers having a small average diameter, and a first layer, which includes fibers having a relatively larger average diameter may be relatively low.
  • the second layer is downstream of the first layer as shown in FIG. 1 .
  • the second layer is a main filter layer and the first layer is a pre-filter layer.
  • the second layer is a downstream main filter layer and the first layer is an upstream filter layer.
  • Other combinations are also possible.
  • the resistance ratio between two layers may be, for example, between 0.5:1 and 15:1, between 1:1 and 10:1, between 1:1 and 7:1, between 1:1 and 5:1, or between 1:1 and 3.5:1.
  • the resistance ratio between the two layers is less than 15:1, less than 12:1, less than 10:1, less than 8:1, less than 6:1, less than 5:1, less than 4:1, less than 3:1, or less than 2:1, e.g., while being above a certain value, such as greater than 0.01:1, greater than 0.1:1, or greater than 1:1.
  • certain ranges of resistance ratios can result in the filter media having favorable properties such as high dirt holding capacity and/or high efficiency, while maintaining a relatively low overall basis weight. Such characteristics can allow the filter media to be used in a variety of applications.
  • the resistance ratio between a main filter layer and a pre-filter layer adjacent (e.g., directly adjacent) the main filter layer of a filter media is between 0.5:1 and 7:1, between 1:1 and 5:1, or between 1:1 and 3.5:1. If the filter media includes another main filter layer, the resistance ratio between the downstream main filter layer to the upstream main filter layer may be between 1:1 and 12:1, between 1:1 and 8:1, between 1:1 and 6:1, or between 1:1 and 4:1. Additional layers are also possible.
  • the resistance of a layer may be normalized against the basis weight of the layer to produce a normalized resistance (e.g., resistance of a layer divided by the basis weight of the layer).
  • a normalized resistance ratio between two layers e.g., a second layer, which includes fibers having a small average diameter, and a first layer, which includes fibers having a relatively larger average diameter, is relatively low.
  • the second layer is a main filter layer and the first layer is a pre-filter layer.
  • the second layer is a downstream main filter layer and the first layer is an upstream filter layer.
  • Other combinations are also possible.
  • the normalized resistance ratio between two layers (e.g., between a second layer and a first layer, between a downstream layer and an upstream layer, between a main layer and a pre-filter layer, or between two main layers, etc.), calculated as the normalized resistance of the layer having a relatively smaller average fiber diameter to the normalized resistance of the layer having a relatively larger average fiber diameter, may be, for example, between 1:1 and 15:1, between 1:1 and 10:1, between 1:1 and 8:1, between 1:1 and 5:1, or between 1:1 and 3:1.
  • the normalized resistance ratio between the two layers is less than 15:1, less than 12:1, less than 10:1, less than 8:1, less than 6:1, less than 5:1, less than 4:1, less than 3:1, or less than 2:1, e.g., while being above a certain value, such as greater than 0.01:1, greater than 0.1:1, or greater than 1:1.
  • the normalized resistance ratio between a main filter layer and a pre-filter layer adjacent (e.g., directly adjacent) the main filter layer of a filter media is between 1:1 and 8:1, between 1:1 and 5:1, or between 1:1 and 3:1. If the filter media includes another main filter layer, the resistance ratio between the downstream main filter layer to the upstream main filter layer may be between 1:1 and 10:1, between 1:1 and 8:1, between 1:1 and 6:1, between 1:1 and 4:1, or between 3:1 and 4:1. Additional layers are also possible.
  • a filter media in another particular set of embodiments, includes a normalized resistance ratio of a second layer to a first layer of 4:1 or greater, and a normalized resistance ratio of a third layer to a second layer of 4:1 or less.
  • a filter media includes a normalized resistance ratio of a second layer to a first layer of between 4:1 and 6:1, and a normalized resistance ratio of a third layer to a second layer of between 2:1 and 4:1.
  • the third layer in such embodiments includes a synthetic polymer fiber having one of the weight percentages described herein.
  • Filter media 10 can also have good dirt holding properties.
  • filter media 10 can have an overall dirt holding capacity (DHC) of at least about 100 g/m 2 , at least about 120 g/m 2 , at least about 140 g/m 2 , at least about 150 g/m 2 , at least about 160 g/m 2 , at least about 180 g/m 2 , at least about 200 g/m 2 , at least about 220 g/m 2 , at least about 240 g/m 2 , at least about 260 g/m 2 , at least about 280 g/m 2 , or at least about 300 g/m 2 .
  • DHC overall dirt holding capacity
  • the dirt holding capacity is tested based on a Multipass Filter Test following the ISO 16889 procedure (modified by testing a flat sheet sample) on a Multipass Filter Test Stand manufactured by FTI.
  • the testing uses ISO A3 Medium test dust manufactured by PTI, Inc. at an upstream gravimetric dust level of 10 mg/liter.
  • the test fluid is Aviation Hydraulic Fluid AERO HFA MIL H-5606A manufactured by Mobil. The test was run at a face velocity of 0.14 meters/min until a terminal pressure of 172 kPa above the baseline filter pressure drop is obtained.
  • the dirt holding capacity of a filter media can be normalized against the basis weight of the media to produce a specific capacity (e.g., dirt holding capacity of the media divided by the basis weight of the media).
  • the specific capacity of the filter media described herein may range, for example, between 1.5 and 3.0, between 1.7 and 2.7, or between 1.8 and 2.5.
  • the specific capacity of a filter media is greater than or equal to 1.5, greater than or equal to 1.6, greater than or equal to 1.7, greater than or equal to 1.8, greater than or equal to 1.9, greater than or equal to 2.0, greater than or equal to 2.1, greater than or equal to 2.2, greater than or equal to 2.3, greater than or equal to 2.4, greater than or equal to 2.5, greater than or equal to 2.6, greater than or equal to 2.7, greater than or equal to 2.8, greater than or equal to 2.9, or greater than or equal to 3.0.
  • the dirt holding capacity of a filter media may also be normalized against the overall basis weight of the media and the log of the filtration ratio (Beta (x) ) for certain particle sizes "x" or greater to produce a unitless value, "Absolute specific capacity at x microns".
  • Beta (x) the log of the filtration ratio
  • the "Absolute specific capacity at 10 microns" for that media would be calculated by multiplying the dirt holding capacity of the media by the square root of the log of the Beta (x) value for 10 micron and larger particles, and dividing by the overall basis weight of the media.
  • a filter media having three (or more) layers has an absolute specific capacity at 10 microns of greater than about 2.5, greater than about 2.65, greater than about 2.7, greater than about 2.75, greater than about 3.0, greater than about 3.4, greater than about 3.5, greater than about 3.6, greater than about 3.75, greater than about 4.0, greater than about 4.25, greater than about 4.5, greater than about 4.75, or greater than about 5.0.
  • the filter media may additionally have a total basis weight of, for example, less than about 200 g/m 2 , less than about 150 g/m 2 , less than about 100 g/m 2 , less than about 90 g/m 2 , less than about 80 g/m 2 , less than about 75 g/m 2 , less than about 70 g/m 2 , less than about 68 g/m 2 , less than about 65 g/m 2 ,less than about 60 g/m 2 , or less than about 50 g/m 2 .
  • Other values and ranges of absolute specific capacity and basis weight are also possible.
  • a filter media having three (or more) layers has an absolute specific capacity at 10 microns of greater than about 2.0, greater than about 2.25, greater than about 2.5, greater than about 2.6, greater than about 2.65, greater than about 2.75, greater than about 3.0, greater than about 3.5, greater than about 3.75, greater than about 4.0, greater than about 4.25, or greater than about 4.5.
  • the filter media may additionally have a total basis weight of, for example, less than about 200 g/m 2 , less than about 190 g/m 2 , less than about 180 g/m 2 , less than about 170 g/m 2 , less than about 160 g/m 2 , less than about 150 g/m 2 , less than about 140 g/m 2 , less than about 130 g/m 2 , less than about 120 g/m 2 , less than about 110 g/m 2 , less than about 100 g/m 2 , less than about 90 g/m 2 , or less than about 80 g/m 2 .
  • Other values and ranges of absolute specific capacity and basis weight are also possible.
  • a filter media described herein includes a relatively high overall dirt holding capacity, such as one of the values described above, and a relatively high overall permeability, such as one of the values described above.
  • a filter media may have an overall dirt holding capacity of at least about 150 g/m 2 (e.g., at least about 180 g/m 2 , at least about 200 g/m 2 , at least about 230 g/m 2 , at least about 250 g/m 2 ), and an overall permeability of greater than about 0.01 m 3 /s (25 CFM) (e.g., greater than about 0.012 m 3 /s (30 CFM), greater than about 0.014 m 3 / s (35 CFM), greater than about 0.016 m 3 /s (40 CFM), greater than about 0.018 m 3 /s (45 CFM), or greater than about 0.02 m 3 /s (50 CFM)).
  • the filter media according to the invention including a third layer comprising a synthetic polymer fiber (e.g., the third layer including at least about 40 wt%, at least about 60 wt%, at least about 80 wt%, at least about 90 wt%, at least about 95 wt%, or about 100% synthetic fibers).
  • the third layer including at least about 40 wt%, at least about 60 wt%, at least about 80 wt%, at least about 90 wt%, at least about 95 wt%, or about 100% synthetic fibers.
  • the filter media described herein may be used for the filtration of various particle sizes, e.g., particles having a size of less than or equal to about 20 microns, less than or equal to about 15 microns, less than or equal to about 10 microns, less than or equal to about 5 microns, less than or equal to about 3 microns, or less than or equal to about 1 micron.
  • the efficiency of filtering such particle sizes can be measured using a Multipass Filter Test. For instance, the efficiency values were determined following the ISO 16889 procedure (modified by testing a flat sheet sample) on a Multipass Filter Test Stand manufactured by FTI. The testing uses ISO A3 Medium test dust manufactured by PTI, Inc. at an upstream gravimetric dust level of 10 mg/liter.
  • the test fluid is Aviation Hydraulic Fluid AERO HFA MIL H-5606A manufactured by Mobil.
  • the test was run at a face velocity of 0.14 meters/min until a terminal pressure of 172 kPa above the baseline filter pressure drop is obtained.
  • Particle counts particles per milliliter
  • upstream and downstream of the media can be taken at ten points equally divided over the time of the test.
  • the average of upstream and downstream particle counts can be taken at each selected particle size. From the average particle count upstream (injected -Co) and the average particle count downstream (passed thru-C) the liquid filtration efficiency test value for each particle size selected can be determined by the relationship [(100-[C/C 0 ]) ⁇ 100%].
  • a mean flow pore size value as described herein (e.g., between about 5 microns and about 50 microns, between about 10 microns and about 30 microns, between about 10 microns and about 20 microns, between 5 microns and 15 microns, between 8 micron
  • the filter media may be produced using processes based on known techniques.
  • the filter media is produced using a wet laid or a dry laid process.
  • a wet laid process involves mixing together the fibers; for example, glass fibers (e.g., chopped strand and/or microglass) may be mixed together, optionally with any synthetic fibers, to provide a glass fiber slurry.
  • the slurry is an aqueous-based slurry.
  • the microglass fibers, and optionally any chopped strand and/or synthetic fibers are stored separately in various holding tanks prior to being mixed together. These fibers may be processed through a pulper before being mixed together.
  • combinations of chopped strand glass fibers, microglass fibers, and/or synthetic fibers are processed through a pulper and/or a holding tank prior to being mixed together.
  • microglass fibers may include fine microglass fibers and coarse microglass fibers.
  • any suitable method for creating a glass fiber slurry may be used.
  • additional additives are added to the slurry to facilitate processing.
  • the temperature may also be adjusted to a suitable range, for example, between 274K(33°F) and 311K (100 °F) (e.g., between 283K (50 °F) and 303K (85 °F)).
  • the temperature of the slurry is maintained. In some cases, the temperature is not actively adjusted.
  • the wet laid process uses similar equipment as a conventional papermaking process, which includes a hydropulper, a former or a headbox, a dryer, and an optional converter.
  • the slurry may be prepared in one or more pulpers. After appropriately mixing the slurry in a pulper, the slurry may be pumped into a headbox, where the slurry may or may not be combined with other slurries or additives may or may not be added.
  • the slurry may also be diluted with additional water such that the final concentration of fiber is in a suitable range, such as for example, between about 0.1% to 0.5% by weight.
  • the pH of the glass fiber slurry may be adjusted as desired.
  • the pH of the glass fiber slurry may range between about 1.5 and about 4.5, or between about 2.6 and about 3.2.
  • the slurry Before the slurry is sent to a headbox, the slurry may be passed through centrifugal cleaners for removing unfiberized glass or shot.
  • the slurry may or may not be passed through additional equipment such as refiners or deflakers to further enhance the dispersion of the fibers.
  • Fibers may then be collected on a screen or wire at an appropriate rate using any suitable machine, e.g., a fourdrinier, a rotoformer, a cylinder, or an inclined wire fourdrinier.
  • the process involves introducing binder (and/or other components) into a pre-formed glass fiber layer.
  • binder and/or other components
  • different components included in the binder which may be in the form of separate emulsions, are added to the glass fiber layer using a suitable technique.
  • each component of the binder resin is mixed as an emulsion prior to being combined with the other components and/or glass fiber layer.
  • the components included in the binder may be pulled through the glass fiber layer using, for example, gravity and/or vacuum.
  • one or more of the components included in the binder resin may be diluted with softened water and pumped into the glass fiber layer.
  • a relatively coarser pre-filter layer may be combined with a relatively finer fiber layer (i.e., a main filter layer) to form a multi-layered filter media.
  • the filter media can include one or more additional finer fiber layers as described above.
  • Multi-phase filter media may be formed in an appropriate manner.
  • a filter media or a portion thereof may be prepared by a wet laid process where a first glass fiber slurry (e.g., glass fibers in an aqueous solvent such as water) is applied onto a wire conveyor to form a first layer.
  • a second glass fiber slurry e.g., glass fibers in an aqueous solvent such as water
  • Vacuum may be continuously applied to the first and second slurries during the above process to remove solvent from the fibers, resulting in the simultaneous formation of the first and second layers into a composite article.
  • the composite article is then dried.
  • At least a portion of the fibers in the first layer can be intertwined with at least a portion of the fibers from the second layer (e.g., at the interface between the two layers).
  • Additional layers can also be formed and added using a similar process or a different process such as lamination, co-pleating, or collation (i.e., placed directly adjacent one another and kept together by pressure).
  • two layers are formed into a composite article by a wet laid process in which separate fiber slurries are laid one on top of the other as water is drawn out of the slurry, and the composite article is then combined with a third layer (e.g., a pre-filter layer) by any suitable process (e.g., lamination, co-pleating, or collation).
  • a third layer e.g., a pre-filter layer
  • filter media or composite article formed by a wet laid process may be suitably tailored not only based on the components of each fiber layer, but also according to the effect of using multiple fiber layers of varying properties in appropriate combination to form filter media having the characteristics described herein.
  • a filter media e.g., a layer and a composite article comprising more than one layer, or two composite articles comprising more than one layer
  • a first layer e.g., a prefilter layer including relatively coarse fibers
  • a second layer e.g., a main filter layer including relatively fine fibers
  • the first and second layers are combined with another main filter layer (e.g., a third layer) using any suitable process before or after the lamination step.
  • three or more layers are laminated together to form a multilayer article. After lamination of three or more layers into a composite article, the composite article may be combined with additional layers via any suitable process.
  • a dry laid process is used.
  • glass fibers are chopped and dispersed in air that is blown onto a conveyor, and a binder is then applied.
  • Dry laid processing is typically more suitable for the production of highly porous media including bundles of glass fibers.
  • one or more layers (e.g., a third layer) of a filter media described herein may be produced from a meltblown process.
  • meltblown processes and manufacturing methods described in U.S. Patent Publication No. 2009/0120048 entitled “Meltblown Filter Medium”
  • Electrospinning processes may also be used to form one or more layers described herein.
  • a synthetic polymer layer may be manufactured and adhered on to a single-phase or multi-phase layer in any appropriate manner.
  • a layer including a synthetic polymer may be positioned downstream with respect to a single-phase or multi-phase layer or vice versa.
  • the layer, composite article or final filter media may be further processed according to a variety of known techniques.
  • the filter media or portions thereof may be pleated and used in a pleated filter element.
  • two layers may be joined by a co-pleating process.
  • filter media, or various layers thereof may be suitably pleated by forming score lines at appropriately spaced distances apart from one another, allowing the filter media to be folded. It should be appreciated that any suitable pleating technique may be used.
  • the physical and mechanical qualities of the filter media can be tailored to provide, in some embodiments, an increased number of pleats, which may be directly proportional to increased surface area of the filter media.
  • the increased surface area may allow the filter media to have an increased filtration efficiency of particles from fluids.
  • the filter media described herein includes 2-12 pleats per 2.54 cm (inch) 3-8 pleats per inch, or 2-5 pleats per 2.54 cm (1 inch). Other values are also possible.
  • the filter media may include other parts in addition to the two or more layers described herein.
  • further processing includes incorporation of one or more structural features and/or stiffening elements.
  • the media may be combined with additional structural features such as polymeric and/or metallic meshes.
  • a screen backing may be disposed on the filter media, providing for further stiffness.
  • a screen backing may aid in retaining the pleated configuration.
  • a screen backing may be an expanded metal wire or an extruded plastic mesh.
  • the filter media disclosed herein can be incorporated into a variety of filter elements for use in various applications including hydraulic and non-hydraulic filtration applications.
  • Exemplary uses of hydraulic filters include mobile and industrial filters.
  • Exemplary uses of non-hydraulic filters include fuel filters (e.g., automotive fuel filters), oil filters (e.g., lube oil filters or heavy duty lube oil filters), chemical processing filters, industrial processing filters, medical filters (e.g., filters for blood), air filters, and water filters.
  • filter media described herein can be used as coalescer filter media.
  • the filter element includes a housing that may be disposed around the filter media.
  • the housing can have various configurations, with the configurations varying based on the intended application.
  • the housing may be formed of a frame that is disposed around the perimeter of the filter media.
  • the frame may be thermally sealed around the perimeter.
  • the frame has a generally rectangular configuration surrounding all four sides of a generally rectangular filter media.
  • the frame may be formed from various materials, including for example, cardboard, metal, polymers, or any combination of suitable materials.
  • the filter elements may also include a variety of other features known in the art, such as stabilizing features for stabilizing the filter media relative to the frame, spacers, or any other appropriate feature.
  • the filter media described herein is incorporated into a filter element having a cylindrical configuration, which may be suitable for hydraulic and other applications.
  • the cylindrical filter element may include a steel support mesh that can provide pleat support and spacing, and which protects against media damage during handling and/or installation.
  • the steel support mesh may be positioned as an upstream and/or downstream layer.
  • the filter element can also include upstream and/or downstream support layers that can protect the filter media during pressure surges. These layers can be combined with filter media 10, which may include three or more layers as noted above.
  • the filter element may also have any suitable dimensions.
  • the filter element may have a length of at least 38.1 cm (15 inches), at least 50.8 cm (20 inches), at least 63.5 cm (25 inches), at least 76.2 cm (30 inches), at least 101.6 cm (40 inches), or at least 114 cm (45 inches).
  • the surface area of the filter media may be, for example, at least 1420 cm 2 (220 square inches), at least 1480 cm 2 (230 square inches), at least 1610 cm 2 (250 square inches), at least 1740 cm 2 (270 square inches), at least 1870 cm 2 (290 square inches), at least 2000 cm 2 (310 square inches), at least 2130 cm 2 (330 square inches), at least 2260 cm 2 (350 square inches), or at least 2390 cm 2 (370 square inches).
  • the filter elements may have the same property values as those noted above in connection with the filter media.
  • the above-noted resistance ratios, basis weight ratios, dirt holding capacities, efficiencies, specific capacities, and fiber diameter ratios between various layers of the filter media may also be found in filter elements.
  • the filter media mechanically trap particles on or in the layers as fluid flows through the filter media.
  • the filter media need not be electrically charged to enhance trapping of contamination.
  • the filter media are not electrically charged.
  • the filter media may be electrically charged.
  • This example describes the formation of several multi-layered filter media and their characterization and is for reference only.
  • Two- and three-layered filter media were prepared according to the specifications listed in Table 1.
  • the two-layered filter media included a first main filter layer (denoted top phase-main filter layer in Table 1) and a second main filter layer (bottom phase-main filter layer) adjacent the first layer.
  • the two-layered media was formed by a wet laid papermaking process. Briefly, for one layer, 0.95 m 3 (250 gallons) of water was added to a hydropulper, then sulfuric acid was added to bring the pH to approximately 3.0. Fibers were added to the mixture, and the fiber and water slurry was mixed for 4 minutes. The slurry was then pumped to a first holding chest with 3.4 m 3 (900 gallons) of additional water. For the second layer, this process was repeated with the fibers needed for the second layer, and the slurry was pumped to a different holding chest.
  • Slurry from the first holding chest was pumped to the main headbox of a fourdrinier papermachine, along with additional water and additional sulfuric acid to reduce the pH to about 2.6.
  • the slurry was allowed to flow onto the forming wire of the papermachine and water was drained by gravity, as well as by a series of vacuum slots eventually forming a wet, loosely bound web of fibers which was carried away by the moving forming wire.
  • fiber from the second holding chest was pumped, along with dilution water, to a secondary headbox also located on the fourdrinier papermaking machine. The secondary headbox was positioned so that the forming wire carrying the drained fibers from the main headbox passed underneath the secondary headbox.
  • This combined single web was then sprayed with a latex solution to add organic binder.
  • the web was then dried by passing over a series of steam filled dryer cans. The now dry web is wound into rolls at a reel.
  • the three-layered filter media included a pre-filter layer as a first layer (pre-filter-single phase), a main filter layer as the second layer (top phase-main filter layer) adjacent the first layer, and another main filter layer (bottom phase-main filter layer) adjacent the second layer.
  • pre-filter-single phase a pre-filter layer as a first layer
  • main filter layer as the second layer
  • bottom phase-main filter layer another main filter layer adjacent the second layer.
  • the second and third layers Prior to assembly with the first layer, the second and third layers were formed simultaneously into a composite article using the same wet laid process as for the two-layered media. The first layer was then assembled with the composite article by collation.
  • This example describes the formation of several single- and multi-layered filter media and their characterization.
  • Comparative Sample 1A had a first (upstream) layer and a second (downstream) layer, the second layer having finer fibers than the first layer.
  • the particular compositions of the first and second layers of Comparative Sample 1A are included in Table 4.
  • the first and second layers were formed using the handsheet protocol described below.
  • Comparative Samples 2-10 are commercial grades from Hollingsworth and Vose Company. As shown in Table 2, all of the comparative samples had absolute specific capacity at 10 ⁇ m values of less than 2.7.
  • Comparative Sample 1B had the same composition as that of Comparative Sample 1A, except the first and second layers were reversed. That is, Comparative Sample 1B had a first (upstream) layer and a second (downstream) layer, the first layer having finer fibers than the second layer. The first and second layers were formed using the handsheet protocol described below.
  • Comparative Samples 11-18 are commercial grades from Hollingsworth and Vose Company.
  • Samples 6-9 are two-layered filter media having various physical characteristics and performance characteristics according to certain embodiments (samples 6-9 are for reference only).
  • the samples labeled "handsheet" in Tables 2 and 3 were formed by a wet-laid handsheet making process.
  • the handsheet mold was prepared using standard procedures. To form a first layer, 5 mL of 25% sulfuric acid was used to acidify the entire volume of the handsheet mold to a pH of 3.0. From this prepared handsheet mold, 750 mL of acidified water was obtained and placed in a Waring 1-speed glass blender. A Variac setting of 60 was used for the pulping level. 4.53 grams of Code 112 fibers and 0.5 grams chopped strand fibers were added to the blender and pulped until well dispersed ( ⁇ 60 seconds). The fiber and water slurry are then added to the top of the handsheet mold, the slurry agitated and then drained through the forming wire. The wet sheet is then vacuumed and dried on a photodryer.
  • the second layer required a modification to the handsheet method described above in that the previously formed first layer was used as a bottom layer sheet, and was placed on the handsheet mold and supported on the edges with blotter paper.
  • the handsheet mold was clamped down and water was carefully added on the side of the mold so as not to disturb the now wet sheet.
  • the water was again acidified with 5 mL of 25% sulfuric acid and 750 mL withdrawn for the secondary layer mixture.
  • the previously weighed 2.42 grams of Code 104 fiber was blended in a Waring 1-speed glass blender for ⁇ 60 seconds and then added to the top of the handsheet mold. The slurry was then carefully agitated so as not to disturb the wet bottom layer and the slurry then drained through the primary layer and the forming wire.
  • the two layer handsheet was then vacuumed and dried on a photodryer.
  • Samples 6 and 7 were formed using the method described in Example 1 and are for reference only.
  • Slurry from the first holding chest was pumped to the main headbox of a fourdrinier papermachine, along with additional water and additional sulfuric acid to reduce the pH to about 2.6.
  • the slurry was allowed to flow onto the forming wire of the papermachine and water was drained by gravity, as well as by a series of vacuum slots eventually forming a wet, loosely bound web of fibers which was carried away by the moving forming wire.
  • fiber from the second holding chest was pumped, along with dilution water, to a secondary headbox also located on the fourdrinier papermaking machine. The secondary headbox was positioned so that the forming wire carrying the drained fibers from the main headbox passed underneath the secondary headbox.
  • the combined web was then dried by passing over a series of steam filled dryer cans. The now dry web is wound into rolls at a reel.
  • Table 4 Composition of Comparative Samples 1A and 1B Sample Bottom Layer Furnish Grams BW (Ibs/r) BW (g/m 2 ) Top Layer Furnish Grams BW (Ibs/r) BW (g/m 2 ) Comparative Samples 1A and 1B JM Code 112 (90%) JM Chop Pak A20 1/2" (10%) 4.53 0.50 33.2 54.0 JM Code 104 2.42 16.0 26.0
  • This example describes the characterization of several single- and multi-layered filter media.
  • FIG. 2 shows the absolute specific capacity at 10 ⁇ m for various filter media plotted against the overall basis weight of the media. The basis weights were plotted on a log scale.
  • Comparative Sample Sets 19 and 20 are two- and three-layered media, respectively.
  • Sample Set 10 are two-layered media formed by the wet laid process described in Example 1.
  • Sample Set 11 are three-layered media including a pre-filter layer, a first main filter layer, and a second main filter layer.
  • the first and second main filter layers were fabricated using the wet laid process described in Example 1 to form a composite article, which was then collated to a pre-filter layer.
  • Sample Set 10 had higher absolute specific capacity at 10 ⁇ m values and lower basis weights than those of Comparative Sample Set 19 (two-layered media).
  • the filter media of Sample Set 10 had absolute specific capacity at 10 ⁇ m values of greater than 3.4 while having a basis weight of less than 75 g/m 2 .
  • the filter media of Comparative Sample Set 19 had absolute specific capacity at 10 ⁇ m values of less than 3.4 while having a basis weight of greater than 75 g/m 2 .
  • Sample Set 11 had higher absolute specific capacity at 10 ⁇ m values and lower basis weights than the filter media of Comparative Sample Set 20 (three-layered media).
  • the filter media of Sample Set 11 had absolute specific capacity at 10 ⁇ m values of greater than 2.65.
  • the filter media of Comparative Sample Set 20 had absolute specific capacity at 10 ⁇ m values of less than 2.65.
  • the basis weights of the Sample Set 11 media was lower than those of the media of Comparative Sample Set 20.
  • FIGS. 3A and 3B are tables showing characteristics of filter media having a first upstream layer including glass fibers, a second layer including glass fibers, and a third downstream layer including meltblown fibers.
  • the first and second layers were formed using a similar process to the one described in Example 1.
  • the third layer was formed using a meltblown process as described herein. As shown in FIGS. 3A and 3B ,relatively high overall dirt holding capacities were achieved while maintaining relatively high overall permeability in certain samples.

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Claims (12)

  1. Milieu filtrant comprenant :
    une première couche comprenant des fibres polymères synthétiques, dans lequel les fibres dans la première couche présentent un premier diamètre moyen ;
    une deuxième couche adjacente à la première couche, la deuxième couche comprenant des fibres polymères synthétiques, dans lequel les fibres dans la deuxième couche présentent un deuxième diamètre moyen, et dans lequel le premier diamètre moyen est supérieur au deuxième diamètre moyen ; et
    une troisième couche adjacente à la deuxième couche, la troisième couche comprenant des fibres polymères synthétiques, dans lequel les fibres dans la troisième couche présentent un troisième diamètre moyen, dans lequel le deuxième diamètre moyen est supérieur au troisième diamètre moyen, dans lequel la troisième couche présente une épaisseur inférieure à 200 microns, et dans lequel la troisième couche présente une taille de pore d'écoulement moyenne comprise entre 5 microns et 50 microns.
  2. Milieu filtrant selon la revendication 1, dans lequel :
    a) la première couche présente une perméabilité à l'air de 2,032 m3/sec/m2 (4 cfm/sf) à 203,2 m3/sec/m2 (400 cfm/sf), ou
    b) la première couche présente un grammage compris entre 5 g/m2 et 70 g/m2 ; ou
    c) la première couche présente une épaisseur comprise entre 76 µm (3 mils) et 1780 µm (70 mils) ; ou
    d) la première couche présente un diamètre de fibre moyen compris entre 1,0 micron et 10,0 microns.
  3. Milieu filtrant selon la revendication 1, dans lequel :
    a) la deuxième couche présente une perméabilité à l'air de 7,62 m3/sec/m2 (15 cfm/sf) à 76,2 m3/sec/m2 (150 cfm/sf). ou
    b) la deuxième couche présente un grammage compris entre 5 g/m2 et 70 g/m2 ; ou
    c) la deuxième couche présente une épaisseur comprise entre 76 µm (3 mils) et 1020 µm (40 mils) ; ou
    d) la deuxième couche présente un diamètre de fibre moyen compris entre 1,0 micron et 9,0 microns.
  4. Milieu filtrant selon la revendication 1, dans lequel :
    a) la troisième couche présente une taille de pore d'écoulement moyenne comprise entre 13 microns et 50 microns ; ou
    b) la troisième couche présente un grammage d'au moins 1 g/m2 et inférieur à 75 g/m2 ; ou
    c) la troisième couche présente une épaisseur d'au moins 30 microns ; ou
    d) la troisième couche présente un diamètre de fibre moyen compris entre 0,8 microns et 5,0 microns ; ou
    e) la troisième couche comprend des fibres de polyester ou de polyamide ; ou
    f) les fibres dans la troisième couche présentent une longueur moyenne comprise entre 2,54 cm (1 pouce) et 254 cm (100 pouces) ; ou
    g) la troisième couche présente un grammage inférieur à 20 g/m2.
  5. Milieu filtrant selon la revendication 1, dans lequel :
    le milieu filtrant présente une efficacité d'au moins 99,5 % pour des particules de 25 microns ou plus, et dans lequel une détermination d'efficacité comprend une utilisation d'un test de filtre Multipass suivant la procédure ISO 16889, qui comprend l'utilisation d'un fluide de test hydraulique, d'un niveau de poussière de 10 mg/litre et d'une vitesse nominale de 0,14 mètre/min jusqu'à ce qu'une pression terminale de 172 kPa au-dessus d'une chute de pression de filtre de base soit obtenue.
  6. Milieu filtrant selon la revendication 1, dans lequel :
    a) un rapport de résistance normalisé de la troisième couche à la première couche est compris entre 1:1 et 8:1 ; ou
    b) la deuxième couche est directement adjacente à la première couche ; ou
    c) la troisième couche est directement adjacente à la deuxième couche.
  7. Milieu filtrant selon la revendication 1, dans lequel :
    a) la première couche inclut moins de 20 % en poids de fibres synthétiques ; ou
    b) les fibres polymères synthétiques de la première, deuxième et/ou troisième couche comprennent des fibres soufflées à l'état fondu ; ou
    c) les fibres polymères synthétiques de la première, deuxième et/ou troisième couche comprennent un matériau choisi dans le groupe consistant en le polyester, le nylon et le sulfure de polyphénylène ; ou
    d) les fibres polymères synthétiques de la première, deuxième et/ou troisième couche sont des fibres soufflées à l'état fondu, filées à l'état fondu, électrofilées à l'état fondu et/ou électrofilées via solvant.
  8. Milieu filtrant selon la revendication 1, dans lequel :
    a) au moins l'une des première et deuxième couches comprend au moins 80 % en poids de fibres de verre ; ou
    b) au moins l'une des première et deuxième couches comprend au moins 40 % en poids de microfibres de verre, dans lequel les microfibres de verre présentent facultativement un diamètre moyen compris entre 1 µm et 6 µm ; ou
    c) au moins l'une des première et deuxième couches comprend au moins 60 % en poids de microfibres de verre ; ou
    d) au moins l'une des première et deuxième couches inclut au moins 80 % en poids de fibres de verre, et la troisième couche inclut au moins 90 % en poids de fibres synthétiques.
  9. Milieu filtrant selon la revendication 1, dans lequel :
    a) la première couche est une couche de préfiltre et présente un grammage supérieur au grammage de la deuxième couche ; ou
    b) un rapport de grammage entre la deuxième couche et la première couche est inférieur à 2:1; ou
    c) au moins l'une des première, deuxième et troisième couches présente un grammage compris entre 10 g/m2 et 100 g/m2 ; ou
    d) les première, deuxième et troisième couches présentent un grammage combiné compris entre 20 et 200 g/m2 ; ou
    f) un rapport de grammages entre la première couche et la troisième couche, ou entre la deuxième couche et la troisième couche, est supérieur à 1:1.
  10. Milieu filtrant selon la revendication 1, dans lequel :
    a) le rapport des premier et deuxième diamètres moyens est inférieur à 2:1 ; ou
    b) le troisième diamètre moyen est inférieur à 1 micron ; ou
    c) le troisième diamètre moyen est inférieur à 1,5 micron ; ou
    e) les fibres de la troisième couche présentent une longueur moyenne de 2,54 cm (1 pouce) à 2 540 cm (1 000 pouces) ; ou
    f) le milieu filtrant présente une épaisseur comprise entre 127 et 7 620 µm (5 et 300 mils).
  11. Milieu filtrant selon la revendication 1 :
    a) dans lequel le milieu filtrant présente une capacité globale de rétention d'impuretés d'au moins 100 g/m2 ; de préférence d'au moins 180 g/m2; plus préférentiellement d'au moins 240 g/m2 ; ou
    b) dans lequel le milieu filtrant présente une capacité globale de rétention d'impuretés d'au moins 150g/m2 et une perméabilité globale supérieure à 12,7 m3/sec/m2 (25 cfm/sf), ou
    c) dans lequel le milieu filtrant présente une perméabilité globale comprise entre 3 cfm/sf et 4 000 cfm/sf, facultativement dans lequel le milieu filtrant présente une perméabilité globale comprise entre 7 cfm/sf et 200 cfm/sf ; ou
    d) la troisième couche présentant une efficacité de Beta(x) = au moins 200 et une taille de pore d'écoulement moyenne de x ± 2 microns ; ou
    e) dans lequel la troisième couche présente une taille de pore d'écoulement moyenne comprise entre 5 microns et 15 microns.
  12. Élément filtrant hydraulique comprenant le milieu filtrant selon la revendication 1, dans lequel la troisième couche est facultativement en aval de la deuxième couche, et la deuxième couche est en aval de la première couche.
EP16185286.8A 2010-10-06 2011-10-05 Milieux filtrants appropriés aux applications hydrauliques Active EP3120915B1 (fr)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
US12/899,512 US8950587B2 (en) 2009-04-03 2010-10-06 Filter media suitable for hydraulic applications
PCT/US2011/054898 WO2012047979A2 (fr) 2010-10-06 2011-10-05 Milieux filtrants appropriés pour des applications hydrauliques
EP11831504.3A EP2624934A4 (fr) 2010-10-06 2011-10-05 Milieux filtrants appropriés pour des applications hydrauliques

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EP3120915B1 true EP3120915B1 (fr) 2020-05-27

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CN114849346A (zh) 2022-08-05
US20110079553A1 (en) 2011-04-07
CN111617557A (zh) 2020-09-04
CN103619437A (zh) 2014-03-05
US10682595B2 (en) 2020-06-16
CN106861293A (zh) 2017-06-20
EP2624934A2 (fr) 2013-08-14
CN103619437B (zh) 2017-03-29
US20180272255A1 (en) 2018-09-27
US20150182885A1 (en) 2015-07-02
CN106861293B (zh) 2020-06-02
US8950587B2 (en) 2015-02-10
EP2624934A4 (fr) 2016-08-17
WO2012047979A3 (fr) 2014-04-03
US9950284B2 (en) 2018-04-24
CN111617557B (zh) 2022-04-12
EP3120915A1 (fr) 2017-01-25
WO2012047979A2 (fr) 2012-04-12

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